Apparatus for making progressive injection molded sheet

ABSTRACT

A plastic sheet is disclosed which is made up of injection molded sections molded progressively and joined together at edges thereof during the molding process. The sheet may have integral bristles on one side thereof making it useful as a rug or carpet, buy other uses of the invention are contemplated. The method includes the molding of plastic sections such that as each section after the first one is molded it welds to a previously molded section at an edge thereof, and the sections are advanced after each molding step so that a trailing edge of the last molded section seals the mold exit. The trailing edge may be provided with a thin flange which is solftened by the molten material so that a weld is formed. Shrinkage of the plastic is controlled to prevent leakage of molten plastic from the mold around the last molded section and also to prevent buckling of the sheet. This is preferably done by providing keys in the mold which harness the plastic to the mold. Pins in the mold are used to form indentations in the sections to facilitate advancing the sections. Other pins slightly oversize in diameter and length serve as a lock for accurate alignment of the sections and also serve a sealing purpose.

Unite States Patet [151 3,655,308 Kutik et al. [451 Apr. 11, 1972 54] APPARATUS FOR MAKING 3,317,644 5/1967 Takai ..18/D1G. s PROGRESSIVE INJECTION MOLDED 3,340,570 9/1967 Korf ...l8/30 UM X SHEET 3,357,058 12/1967 Kutik l 8/DlG. 8 3,507,010 4/1970 Daleman et al.... ..l8/21 [72] Inventors: Louis F- Kutik, 72 -W- 2 r aC 3,577,843 5/1971 Kutik et a1. l 8/D1G. 8

Fort Lauderdale, Fla. 33314; Erich W. Gr n m y 2100 Ocean Lane, Fort Primary ExaminerJ. Howard Flint, Jr. Lauderdale, 33316 Att0rneySettle and Oltman [22] Filed: Apr. 30, 1971 ABSTRACT [2]] Appl' 138894 A plastic sheet is disclosed which is made up of injection Related US, li i D molded sections molded progressively and joined together at I edges thereof during the molding process. The sheet may have [62] Dlvlslon of 729694 May 1968 integral bristles on one side thereofmaking it useful asa rug or carpet, buy other uses of the invention are contemplated. The method includes the molding of plastic sections such that as [52] U.S. Cl ..425/109, 156/500, 249/95, each Section after the first one is molded it welds to a previ 2264/ g ously molded section at an edge thereof, and the sections are [51] "Bzgd 7/0 829d H0 B29 f advanced after each molding step so that a trailing edge ofthe last molded section seals the mold exit. The trailing edge may [5 8] F'eld f gg gi gfg g be provided with a thin flange which is solftened by the molten 18/ 24 l material so that a weld is formed. Shrinkage of the plastic is R f d controlled to prevent leakage of molten plastic from the mold [5 6] e erences I e around the last molded section and also to prevent buckling of UNITED STATES PATENTS the sheet. This is preferablydone by providing keys in the mold which harness the plastic to the mold. Pins in the mold 2,47 l Bolten are used to form indentations in the sections to facilitate ad- 2,783,501 3/1957 Kutlk 8 vancing the sections. Other pins slightly oversize in diameter 2,979,776 4/1961 Morin ls/DIG 34 and length serve as a lock for accurate alignment of the sec- 3,065,481 1 l/l 962 Peterson l 8/DIG. 8 {ions and also serve a Seaiing purpose 3,098,262 7/1963 Wisotgky .....l8/D1G. 8 3,192,298 6/1965 Fisher ..1 8/30 UM X 11 Claims, 16 Drawing Figures 66 16s- I I76 ilji j fbzziiija- Q I66 7" h 7--Iw att Q PATENTEDAPR 11 1972 3. 655,308

sum 1 OF 7 FIG. 2

FIG. 3

INVENTORS ERICH W GRONEMEYB?. BY LOUIS F KUTIK.

ATT'Y.

PATENTEDAPR 11 m2 3,655,308

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INVENTORS ERICH W. GRONEMEYER LOUIS F KUTIKA PATENTEBAPR 1 1 I972 SHEET 3 OF 7 Ok v QQTLAII IIIIIFVIfiIMLII INVENTORS ERICH W GRONEME YER. LOUIS F KUTIK.

m GE

PATENTED PR H I972 3,655,308

sum u. 0F 7 INVENTORS ERICH w GRONEMEYER; FIG. 7 BY LOUIS f-T KUTIK.

PATENTEDAPR 1 I 1972 SHEET 8 BF 7 FIG. 9

INVENTORS ERICH W GRONEMEYER.

LOUIS F KUTIK.

ATTx

PATENTEDAPR 11 m2 3.655.308

SHEET 7 OF 7 FIG. 12 FIG. 13

7 g [A310 I44 I IN Vlz'N'H )RS ERICH W. GRONEME YER. LOUIS F. KUTIK.

APPARATUS FOR MAKING PROGRESSIVE INJECTION MOLDED SHEET RELATED APPLICATION This application is a division of co-pending application Ser. No. 729,694 filed May 16, 1968 now US. Pat. No. 3,616,110.

BACKGROUND OF THE INVENTION The invention is concerned with plastic sheets, and particularly sheets which may be molded with integral bristles such that they may be used for rugs or carpets. On the other hand, sheets without bristles may be used as panels and could be provided with appropriate decoration.

It would be extremely difi'icult and expensive to injection mold a large plastic sheet with or without bristles in a single molding step. Obviously, a mold as large as the product would be required, and in the case of sheets for use as rugs or carpets, the mold cavity would have to be very large in area. Not only would such a mold be expensive, but extreme holding forces would be required. Difficulties would also be encountered in filling the mold with plastic, partly because molten plastic becomes chilled as it enters the cavity and solidifies, thus tending to block access to some portions of the cavity.

The present invention contemplates an apparatus for injection molding of sections of a sheet and joining the sections together as they are molded. Some special problems are encountered in this process, but they have been overcome satisfactorily. For example, provisions must be made to assure that a newly molded section will adhere or join to the last previously molded section. Problems are also encountered because of shrinkage of the plastic. Specifically, a previously molded section must seal the mold cavity, but undue shrinkage of that section could allow molten material to leak out of the cavity. Such shrinkage could also cause steps to form at the side edges of the sheet and could cause buckling of the sections.

SUMMARY OF THE INVENTION The invention provides a molding apparatus for making a plastic sheet made up of sections which are progressively injection molded and joined together, preferably by welding or fusing of the plastic at the joints. The sections may be square or rectangular, the rectangular form being preferred because very wide rectangular sections may be molded and joined together along their long edges to build up a large sheet. Bristles may be formed as integral parts of the sheets where they are to be used as carpeting.

To assure that the newly molded section will weld to the last previously molded section, the trailing edge of each section is provided with a very thin flange or extension having a large surface area and reduced thickness, which is softened by the molten plastic, thus causing the next-molded section to weld to the flange during the molding operation. There must be some way to advance the sections as they are molded, and pins are provided for this purpose in accordance with the inventron.

When a large molded section cools, it unavoidably shrinks greatly. Depending on size, such shrinkage will range from a fraction of an inch to an inch or more. It can be seen that where the newly molded section joins the previously molded section, this shrinkage could cause buckling of the previously molded section. Also, the previously molded section is sealed in the mold cavity by, in effect, utilizing the previously molded section to form one side of the mold. If the previously molded section has shrunk too much, there will be a gap between this section and the mold through which molten plastic can escape from the mold.

These thermal shrinkage problems have been solved by harnessing the plastic material to the mold to control shrinkage. The harnessing is preferably done by providing keys in the die or the mold as will be explained. These keys prevent undesirable shrinkage over the width of a section so that no large gaps will form at the side edges of the section through which molten plastic can escape from the mold. The shrinkage which occurs over the length of the section is not harmful. Because shrinkage is controlled in the manner just described, no buckling or misalignment of the sections occurs.

Accordingly, it is an object of the present invention to provide an apparatus for making a plastic sheet which is molded by progressive injection molding.

Another object of the invention is to provide an apparatus for making a plastic sheet comprising progressively injection molded sections welded or fused together at edges thereof.

Another object of the invention is to provide an apparatus for molding a plastic sheet by successively molding plastic sheet sections and simultaneously joining each such newly molded section to the last previously molded section.

Still another object is to provide an apparatus for progressive injection molding in which one set of pins are used in the mold to fonn indentations in each section, and other pins slightly oversize in diameter and length are inserted into the indentations, so as to serve as a lock for accurate alignment of the sections and also to serve a sealing purpose.

Yet another object of the invention is to provide an apparatus for progressive injection molding in which shrinkage of a previously molded section (which can be very undesirable) is substantially prevented across the width dimension of the section by harnessing the section to the mold with longitudinally extending keys.

Other objects of this invention will appear in the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.

ON THE DRAWINGS:

FIG. 1 is a perspective view of a progressive injection molded sheet having integral bristles on the upper side thereof;

FIG. 2 is a fragmentary sectional view of the sheet taken along line 22 of FIG. 1;

FIG. 3 is a fragmentary sectional view of the sheet taken along line 3-3 of FIG. 1;

FIG. 4 is a plan view, partly in section, showing the lower part of a mold and associated advancing apparatus for molding the sheet ofFIG. 1;

FIG. 5 is a vertical sectional view of the apparatus of FIG. 4 at a stage where a section of a sheet has been molded;

FIG. 6 is a fragmentary sectional view of a portion of the apparatus shown in FIG. 5 at a stage where the mold is open;

FIG. 7 is a vertical sectional view of the apparatus at a stage where a section of a sheet has been advanced;

FIG. 8 is a vertical sectional view of the apparatus after the mold has been closed and a starting adaptor has been removed;

FIG. 9 is a vertical sectional view of the apparatus after several sections of a sheet have been progressively injection molded and welded together during the molding;

FIG. 10 is an enlarged view of a portion of the apparatus of FIG. 9;

FIG. 11 is a fragmentary sectional view taken along line 1111 ofFIG. 4;

FIG. 12 is a schematic plan view of a newly molded plastic section joined to a previously molded section illustrating how undesirable shrinkage of the previously molded section causes irregular or stepped side edges to form on a sheet, the shrinkage also leading to buckling of the sheet;

FIG. 13 is a schematic plan view illustrating a newly molded section joined to a previously molded section where undesirable shrinkage has been prevented;

FIG. 14 is a fragmentary sectional view taken along line 14-14 of FIG. 12 showing gaps between the side edges of the section and the mold through which molten plastic can leak;

FIG. 15 is a fragmentary sectional view taken along line 1515 of FIG. 13 illustrating how the width dimension of a plastic section can be maintained to avoid gaps like those shown in FIG. 14 by harnessing the plastic to the mold; and

FIG. 16 is a fragmentary sectional view illustrating a joint between two progressive injection molded sections.

Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways, Also, it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

AS SHOWN ON THE DRAWINGS:

THE MOLDED PRODUCT Referring first to FIGS. 1, 2 and 3, a progressive injection molded plastic sheet 20 is shown, the sheet being homogeneous and having upper and lower major surfaces 22 and 24 with monofilament bristles 26 extending from and integral with upper surface 22. One use for the sheet 20 is as carpeting, and for a sheet of this type the bristles 26 are made to be hair-like; i.e., they are vey fine and provide a nap on the sheet 20. It is to be understood that progressive injection molded sheets in accordance with the invention need not have bristles on them for some applications. For example, where the sheet is to be used as paneling, it may be planar or may have a design molded into surface 22. The sheet may be made in various colors.

For purposes of identification, the dimension of the sheet between edges 28 and 30 will be referred to as the length of the sheet, and the dimension between edges 32 and 34 will be referred to as the width of the sheet. Consequently, edges 28 and 30 are the end edges, and edges 32 and 34 are the side edges. The edges and dimensions of individual sections of the sheet will be identified similarly.

The bottom or backing surface 24 of the sheet is provided with continuous undercut or re-entrant recesses or slots 36 which extend the full length of the sheet between end edges 28 and 30. Slots 36 have recessed base surfaces 38 and slanting side surfaces 40 and 42. It is apparent that the slots taper from a narrow dimension at surface 24 to a wider dimension at surface 38.

Sheet 20 is made up of a plurality of plastic sections 40, two such sections 40a and 40b being shown in FIG. 3. Each section extends over the full width of the sheet 20. Sections 40a and 40b are welded or fused together at a joint 42 which is at the trailing edge of section 40b and the leading edge of section 40a. For purposes of identification, the length of a section such as 400 will be considered to be the dimension between edge 28 and joint 42, the width of the section being the same as the width of sheet 20. Ordinarily, the width of each section will be considerably greater than its length because in this way large sheets can be built up. However, it is contemplated that the sections may be square for some applications.

The bottom or backing side 24 of each section is provided with at least one row of indentations 46, these indentations being aligned across the width of the section as shown in FIG. 2. lndentations 46 are formed by one set of pins when a given section is molded, and thereafter they receive other pins which serve to lock the sections in place while a new section is molded and also to advance the sections as will be described further.

As shown in FIG. 3 the trailing edge of section 40b has a thin flange 48 extending therefrom into section 40a. The material of section 400 is welded or fused to the material of flange 48, and this welding or fusing takes place as a given section is molded. The joining together of sections will be described more fully when the method subject matter of the invention is considered later, but it may be noted at this point that flange 48 is very thin and tapers to a sharp edge at 50 so that it can be softened readily by hot molten plastic to facilitate joining. The trailing edge of section 40a has a flange at the time it is molded, but this flange is removed to provide one edge 28 of the sheet. All of the other sections of the sheet have a flange 48 embedded in and welded to an adjoining section.

Polyethylene is one suitable material for the sheet, but others may be used.

The sheet 20 may be made sufficiently thin and flexible to allow it to be rolled up for shipment and storage purposes. The slots 36 serve more than one purpose, and one of these purposes is connected with anchoring sheet 20 to a mounting surface such as a floor. Slots 36 may be filled with adhesive which will be exposed at surface 24 and will adhere to the floor. The adhesive need not bond to the plastic of sheet 20 because the undercut nature of recesses 36 means that the adhesive, after it hardens, forms an interlocking connection to the sheet which will hold it in place.

THE INJECTION MOLD FIGS. 4-9 illustrate one embodiment of apparatus for molding the sheet 20 by progressive injection molding, and also illustrate the steps of the method of progressive injection molding. Referring first to FIGS. 4 and 5, the apparatus 52 includes a base plate 54 on which vertical support walls 56,58 and 60 are mounted. Side walls 62 and 64 are connected to wall 60 (FIG. 4), and a top wall 66 is connected to vertical wall 60.

The apparatus includes two main sections, a mold section designated generally 68 and a puller section designated generally 70. Mold section 68 includes superposed plates 72 and 74 mounted in stationary positions on top of vertical walls 56 and 58. The upper surface 76 of plate 72 is shaped to form the bottom major side of the mold cavity 78. Above plate 72 is a vertically movable plate 80 which has a lower surface 82 shaped to form another boundary or major side of the mold cavity 78. It may be noted that recesses are shown in plate 80 for forming bristles on plastic sections as they are molded, but the size of these recesses is greatly exaggerated because it would be impossible to show recesses as fine as those actually used. The upper mold member 80 is preferably a plurality of blades joined together in the manner described and claimed in U.S. Pat. No. 3,357,058, of Louis F. Kutik, one of the present inventors, to form a mold for molding bristles on a sheet. The drawings have been simplified in the present application by showing only crude and enlarged bristle forming cavities.

An adaptor 83 is recessed at 84 for the purpose of molding an extension 86 on the first plastic section which is molded to enable that section to be advanced from the mold. The adaptor 83 is removed from the apparatus at a later stage of the method as will be described.

A small wedge-shaped strip 88 is mounted on the upper side of mold member 72 to define the tapered flange 48 on the trailing edge of each plastic section. There is also a small projecting ridge 90, shown more clearly in FIG. 10, which molds a recess at the base of projection 48 for receiving a sealing projection 92 after the plastic section has been advanced. The mold cavity 78 for molding a plastic section effectively ter minates at projection 92 to form an open side of the mold cavity, except that when the first plastic section is being molded as in FIG. 5, the cavity 76 is extended by the adaptor 84 to form the extension 86 on the first plastic section.

Hot plasticized plastic material is injected under pressure into cavity 76 from a passageway 94 extending through mold member 80 and structure provided above it, and in FIG. 4 three such passageways 94 are indicated. Three gates 96 communicate respectively with passageways 94 and the mold cavity 76. Gates 96 may be defined by inserts 98. The gates are spaced along the width of mold cavity 76 closely enough that the hot plasticized plastic material injected into the cavity through the gates will not solidify completely before the cavity is filled. Directly under passageways 94 are vertically movable stripper rods 100 which extend through plates 72 and 74 and are connected at their lower ends to vertically movable bars 102 and 104. Bars 102 and 104 may be raised by operation of an external pneumatic or hydraulic cylinder connected to the bars by a piston 106. The stripper rods 100 are shown in their lowered positions in FIG. 5.

Extending vertically through plates 72 and 74 are a first set of molding pins 108. These molding pins are movable vertically, and are shown in a raised position in FIG. 5 wherein the tips of the pins project into mold cavity 76. The pins 108 mold the indentations 46 (FIGS. 2 and 3) into each plastic section. The lower ends of pins 108 have heads 110 which lock into recesses in a pin bar 112 which is urged downwardly by springs 114 provided between bar 112 and plate 74 as shown in FIG. 5. Another bar 116 is connected to bar 112 and bears against cams 118 provided on shafts 120 extending horizontally outward from the apparatus 52. Bars 112 and 116 along with pins 108 are shown in a raised position in FIG. 5. By rotating shafts 120, cams 118 are turned until a flat or low point thereof is in contact with plate 116, thereby lowering bars 112 and 116 along with pins 108 to remove the tips of pins 108 from the mold cavity and from the molded indentations 46.

A second set of pins 122, hereinafter referred to as locking pins," extends vertically through plates 72 and 74, and their lower ends are also connected to pin bar 112. Thus, when bars 112 and 116 are raised or lowered, the second set of pins 122 are also raised or lowered as the case may be. The purpose of ins 122 is to extend into the indentations 46 in a previously molded section to lock that section in place with its trailing edge blocking or sealing the exit end of the mold cavity 76. The locking pins 122 are aided in this function by the locating projection 92 (FIG. and also by upper pins 124 which project downwardly from mold member 80 directly opposite pins 122. Thus, both pins 122 and 124 engage a previously molded section to lock it in place. However, at the stage shown in FIG. 5, an extension 86 is being molded on the first section, so the pins 122 mold indentations into the extension.

The locking pins 122 may be slightly longer and larger in diameter than the molding pins 108, so that pins 122 slightly expand the plastic material about them to help insure that the plastic material firmly contacts the adjoining metal surfaces to prevent escape of molten materials from the mold cavities 76. This will be more apparent from FIG. 8.

The surface 76 of mold member 72 is provided with a plurality of longitudinally extending keys 126 which are visible most clearly in FIGS. 11 and 15. These keys are undercut so that they have the cross sectional shape of the recesses 36 discussed in connection with FIG. 2, and of course the keys 126 mold the recesses 36 into the plastic sheet. It may be noted that keys 126 extend longitudinally all the way through mold cavity 78 and well beyond the mold cavity to a terminal edge at 128 shown in FIG. 4. Thus, in addition to molding the recesses 36 into a newly molded section, the keys serve to anchor a previously molded section in alignment with the newly molded section. The keys 126 interlock with the plastic material because of the undercutting thereof so that they hold down a newly molded section when the upper mold member 80 is moved vertically as in FIG. 6, thus pulling the bristles out of the bristle molding cavities 82.

The keys 126 serve another very important function which will be described with reference to FIGS. 12-15. These figures are somewhat schematic since they are intended to illustrate only how the keys 126 prevent undesirable shrinkage of the plastic material. In FIG. 12, there is shown a previously molded plastic section 130 and a newly molded plastic section 132 in a mold member 134 as they would appear immediately after molding the section 132, assuming that no keys or other retention means are provided to prevent shrinkage across the width of the sections. The previously molded section 12 shrank considerably across its width between edges 138 and 140. Consequently, as shown in FIG. 14 there are gaps 142 and 144 between side edges 138 and 140 and the adjoining side edges 142 and 144, respectively, of the mold. Previously molded section 130 actually forms one side wall of the mold cavity in which section 132 is molded. Thus, when molten plastic is injected under high pressure into the mold cavity, it can escape from the cavity through gaps 142 and 144. The shrinkage will be between 0.008 and 0.015 inch per inch of material. and thus it is apparent that the gaps 142 and 144 may be quite large depending on how wide section 130 is. If gaps 142 and 144 are larger than about 0.002 inch, molten plastic can easily extrude from the mold cavity through these gaps.

Another problem caused by such shrinkage is apparent from FIG. 12. It may be seen that where section 132 joins section along edge or joint 146 steps are formed at 148. These steps make irregular side edges on the sheet, and are undesirable for this reason alone. In addition, as newly molded section 132 shrinks, tension will be exerted along joint 136 which may cause previously molded section 130 to buckle.

FIGS. 13 and 15 illustrate the results which are achieved when keys 126 are provided on the bottom mold 134 to prevent undesirable shrinkage of the plastic material across the width of a section. These keys harness the plastic material to the mold to maintain the desired width dimension between edges 138 and 140. Shrinkage in width occurs mainly between each pair of keys. The only shrinkage of edges 138 and 140 is due to the material between the side edges 142 and 144 of the mold and the first adjacent keys 126a and 126b. If this dimension is less than say Vs of an inch, the width shrinkage will be negligible, and no molten plastic material can escape from the molds. The thickness of the sheet is always very small, so that shrinkage across this dimension is also negligible. Shrinkage across the length of a section, i.e., between edges and 146 is not harmful since it does not break the seal of the mold and does not effect the adjoining section.

As a result of the effect of the keys 126, sections 130a and 132a have the same width as shown in FIG. 13, and there are no irregular side edges or steps.

THE PULLING APPARATUS Referring again to FIGS. 5-9, the pulling apparatus 70 will now be described. An actuating rod 152 is attached by a coupling member 154 to a vertical support plate 156. Horizontal plates 158, and 162 are attached to vertical plate 156, and the adaptor 83 fits between plates 160 and 162. Lower shafts 164 are joumaled for rotation in plates 58 and 156, and upper shafts 166 are joumaled for rotation in plates 60 and 168.

Cams 170 are slidably keyed to shafts 164 by keys 172 fitting in slots 174. Similar cams 176 are slidably keyed to upper shafts 166 by keys 178 fitting in slots 180. The lower cams 170 engage one of two pin bars 182 and 184, and the upper cams 176 engage the upper one of two pin bars 186 and 188.

Two lower sets of pins and 192 extend through plates 158 and 160, and have head engaging pin bar 184 so that they will move vertically with pin bar 184. Similarly, two upper sets of pins 194 and 196 extend through plate 162 and adaptor 82, and have heads engaged by pin bar 188 so that the pins will move vertically with the pin bar. Pins 190, 192, 194 and 196 are shown in FIG. 5 in a closed position. Pins 190 and 192 are moved down by rotating shafts 164, and pins 194 and 196 are moved up by rotating shafts 166. This movement of the pins is produced by springs 198 and 200 which respectively bias pin bars 184 and 188 so that these pin bars follow the cams 170 and 176 when they are rotated to a flat or low point.

The whole pulling mechanism 70 is movable horizontally along shafts 164 and 166 when shaft 152 is pulled to the right and the mold is open to expose the molded product, as viewed in FIG. 7. Since pins 190, 192, 194 and 196 grip the plastic sheet which has been molded, this movement of pulling mechanism 70 advances the sheet to pull the newly molded section out of the mold leaving only its trailing edge at the exit end of the mold cavity to seal the mold when it is closed. After the mold is reclosed as in FIG. 8, the shafts 164, 166 are rotated to open the pulling mechanism, the rod 152 is extended to the left, the pulling mechanism is advanced to the mold and reclosed, as best shown in FIG. 9.

THE METHOD The steps of the method will be described starting with the apparatus 52 positioned as shown in FIG. 5. Molten plastic is injected through passageways 94 and gate 96 into the mold cavity 78 under very high pressure. The plastic material fills the bristle forming cavities 82 and also the extension 84 of the mold cavity formed by the adaptor 83. A flange 48 is formed on the trailing edge of the newly molded section 40. Indentations 46 are molded by pins 108 and slots 36 are molded by keys 126.

After the plastic has solidified, the upper mold member 80 is raised in the manner shown in FIG. 6. Shafts 120 are rotated to pull pins 108 and 122 out of the mold cavity. Rod 106 is raised to, in turn, raise rods 100 and thus push the waste plastic material 121 out of gate 96. The waste material then can be removed, either manually or mechanically.

Next, pulling mechanism 70 is moved to the right to the position shown in FIG. 7 by pulling on the shaft 152. This advances newly molded section 40 to the right through a stroke such that the indentations 46 formed in this section register with pins 122.

Rod 106 is lowered to pull rods 100 down out of the gate 96. Upper mold member 80 is lowered down on to mold member 72 to reform the mold cavity 78, as shown in FIG. 8. It may be noted that the trailing edge of sheet section 40 fills the exit end of the mold cavity 78 with flange 48 projecting into the mold cavity. Pins 108 and 122 are raised by rotating shafts 120, and pins 122 enter the indentations 46 in section 40. The opposed pins 124 engage plastic section 40 on its upper side directly opposite pins 122, and these two sets of pins lock plastic section 40 in place. The relationship of these pins is also shown enlarged in F IO. 11. The projection 92 fits in the small recess at the base of flange 48 to further lock section 40 in place and also to aid in sealing section 40 at the exit end of cavity 78. As previously pointed out, pins 122 are slightly larger in length and diameter than pins 108 so that pins 122 expand the plastic slightly forcing it against keys 126 to further help in sealing the exit end ofthe mold cavity.

Also as shown in FIG. 8, shafts 164 and 166 are rotated to pull pins 190, 192, 194 and 196 back to release extension 86. The pulling mechanism 70 is then pushed to the left to bring it back to the position shown in FIG. except that the pins of this mechanism will then be registered with different sets of indentations in extension 86.

The apparatus is then ready for another injection step. It may be noted from FIG. 8 that the flange 48 is located centrally between top and bottom surface of cavity 78. The reason for this is that when molten material is injected into the cavity, the hot material is at the center of the cavity, the outer material being chilled by the mold walls. Thus, the hottest material softens the flange 48 and welds or fuses to it. Flange 48 is sufficiently thin that heat transferred to it from the molten material raises its temperature substantially without all of the heat being dissipated immediately to the thicker material in the main part of sheet section 40. This facilitates softening of flange 48.

FIG. 9 shows the condition of the apparatus after several plastic sections have been molded progressively and welded together to form a sheet. A portion of this sheet is shown enlarged in F IG. to better show the relationship of the parts.

It may be noted in FIG. 9 that pins 190 and 192 enter in dentations 46 in previously molded sections and pins 194 and 1% contact these sections opposite pins 190 and 192 so that the sheet can be advanced by pulling the whole pulling mechanism 70 to the right.

From the foregoing description it is apparent that the invention provides an apparatus for manufacturing a sheet by progressive injection molding and which sheet is useful as carpeting, paneling or in other applications.

FIG. 16 shows a modification of the flange 48. The flange is molded with apertures extending through it, and this can be accomplished by providing suitable pins on the mold such as on wedge-shaped plate 88. When the newly molded section 40 is advanced, it is then in a position shown in FIG. 16. When molten plastic material is injected into the mold cavity, it enters the opening in flange 48 from both sides and thus forms continuous stitches 49 extending through the openings in flange 48. The hot plastic also welds to flange 48, and the stitches 49 provide a further anchoring of the new material to flange 48.

Having thus described our invention, we claim:

1. Apparatus for use in progressive injection molding of plastic sheets including in combination mold means forming a mold cavity of thin flat configuration with major sides for molding a section of a plastic sheet, said cavity when closed having an open side with a small thickness dimension corresponding to the thickness of said sheet and a width dimension considerably greater than said thickness dimension and corresponding to the width of said sheet, means for positioning a previously molded sheet section with a trailing edge thereof within and blocking said open side of said cavity, means for injecting hot plasticized plastic material into said cavity to mold a sheet section and simultaneously fuse the same to the trailing edge of the previously molded section, said mold means have means on at least one of the major sides of said cavity to harness the plastic material to the mold to inhibit undesired shrinkage of the plastic, and means for advanc ing said sections to position the trailing edge of the newly molded section within and blocking said open side of said cavity to prepare for molding a further section and fusing the same to said newly molded section.

2. The apparatus as claimed in claim 1 in which said cavity of said mold means has means shaped to mold a flange at the trailing edge of each sheet section with the flange being thinner than the sheet section so that hot plasticized material can soften the same and fuse thereto when injected into said mold cavity.

3. The apparatus as claimed in claim 1 in which said means to inhibit shrinkage includes a plurality of key means on said one major side of the mold means extending in the direction of advancement of said sections for the harnessing of the plastic to said mold means to prevent the undesirable shrinkage of the plastic away from side edges of the mold cavity.

4. The apparatus as claimed in claim 3 in which said key means are undercut to anchor the plastic but allow said advancement movement thereof.

5. The apparatus as claimed in claim 4 in which the other of said major sides of said mold means includes bristle forming recesses for molding bristles integral with the corresponding side of each sheet section.

6. The apparatus as claimed in claim 1 in which said mold means includes first retractable pins projecting into said cavity for molding indentations in each sheet section and further includes second retractable pins outside said cavity for engaging the indentations in a previously molded section to lock the same in place.

7. The apparatus as claimed in claim 6 in which said second pins are slightly larger in length and diameter than said first pins so as to expand the plastic against the mold means.

8. The apparatus as claimed in claim 7 in which said advancing means includes further pins engageable with the indentations in sheet sections outside said cavity.

9. In a molding apparatus for successively making and joining separate sheet sections into a composite sheet of continuous length by injection molding the sections in a mold having relatively movable parts cooperably defining therebetween a mold cavity conforming to one of said sections and open at one end through which the successive sections are withdrawn with a portion of each successive molded section projecting through said open end to be joined to the next-molded section, the improvements of a plurality of transversely spaced keyway means located in said mold cavity on at least one major side of said mold and extending along the direction of withdrawal of said successive sections for preventing sideways thermal shrinkage of said sections after injection molding, said open end of said mold cavity when closed having a small thickness dimension corresponding to the thickness of said sheet and a width dimension considerably greater than said thickness dimension and corresponding to the width of said sheet,. and

means located exteriorly of said mold cavity for engagement with the immediately preceding section to prevent displacement of said preceding section during injection molding of the next successive section.

10. In an injection molding apparatus for making an elongated, continuous bristled product formed of integrally joined thin and wide strips having individual spaced bristles integral with a continuous backing; a pair of relatively openable and closable mold sections defining, when closed, a mold cavity conforming to one of said strips one of said mold sections having bristle-defining components; means for injecting plasticized material under pressure into said cavity when said sections are closed; means engageable with a previously formed strip to remove said strip from said cavity when said sections are open; means to inhibit sideways shrinkage of said strip and means on each of said sections engageable with a different previously formed strip upon the next closing of said sections to position and retain said different strip against the pressure of injection of the next successive strip.

11. An injection molding apparatus as defined in claim 10, wherein said different strip is the one immediately previously injection molded and said last named means includes spaced projections on one of said moldsections stabilizing said different strip in one direction against the pressure of injection and, said mean s to inhibit shrinkage comprises different spaced projections on one of the mold sections stabilizing said strip against thermal shrinkage. 

1. Apparatus for use in progressive injection molding of plastic sheets including in combination mold means forming a mold cavity of thin flat configuration with major sides for molding a section of a plastic sheet, said cavity when closed having an open side with a small thickness dimension corresponding to the thickness of said sheet and a width dimension considerably greater than said thickness dimension and corresponding to the width of said sheet., means for positioning a pReviously molded sheet section with a trailing edge thereof within and blocking said open side of said cavity, means for injecting hot plasticized plastic material into said cavity to mold a sheet section and simultaneously fuse the same to the trailing edge of the previously molded section, said mold means have means on at least one of the major sides of said cavity to harness the plastic material to the mold to inhibit undesired shrinkage of the plastic, and means for advancing said sections to position the trailing edge of the newly molded section within and blocking said open side of said cavity to prepare for molding a further section and fusing the same to said newly molded section.
 2. The apparatus as claimed in claim 1 in which said cavity of said mold means has means shaped to mold a flange at the trailing edge of each sheet section with the flange being thinner than the sheet section so that hot plasticized material can soften the same and fuse thereto when injected into said mold cavity.
 3. The apparatus as claimed in claim 1 in which said means to inhibit shrinkage includes a plurality of key means on said one major side of the mold means extending in the direction of advancement of said sections for the harnessing of the plastic to said mold means to prevent the undesirable shrinkage of the plastic away from side edges of the mold cavity.
 4. The apparatus as claimed in claim 3 in which said key means are undercut to anchor the plastic but allow said advancement movement thereof.
 5. The apparatus as claimed in claim 4 in which the other of said major sides of said mold means includes bristle forming recesses for molding bristles integral with the corresponding side of each sheet section.
 6. The apparatus as claimed in claim 1 in which said mold means includes first retractable pins projecting into said cavity for molding indentations in each sheet section and further includes second retractable pins outside said cavity for engaging the indentations in a previously molded section to lock the same in place.
 7. The apparatus as claimed in claim 6 in which said second pins are slightly larger in length and diameter than said first pins so as to expand the plastic against the mold means.
 8. The apparatus as claimed in claim 7 in which said advancing means includes further pins engageable with the indentations in sheet sections outside said cavity.
 9. In a molding apparatus for successively making and joining separate sheet sections into a composite sheet of continuous length by injection molding the sections in a mold having relatively movable parts cooperably defining therebetween a mold cavity conforming to one of said sections and open at one end through which the successive sections are withdrawn with a portion of each successive molded section projecting through said open end to be joined to the next-molded section, the improvements of a plurality of transversely spaced keyway means located in said mold cavity on at least one major side of said mold and extending along the direction of withdrawal of said successive sections for preventing sideways thermal shrinkage of said sections after injection molding, said open end of said mold cavity when closed having a small thickness dimension corresponding to the thickness of said sheet and a width dimension considerably greater than said thickness dimension and corresponding to the width of said sheet,. and means located exteriorly of said mold cavity for engagement with the immediately preceding section to prevent displacement of said preceding section during injection molding of the next successive section.
 10. In an injection molding apparatus for making an elongated, continuous bristled product formed of integrally joined thin and wide strips having individual spaced bristles integral with a continuous backing; a pair of relatively openable and closable mold sections defining, when closed, a mold cavity conforming to one of said strips, one of said mold sections having bristle-defiNing components; means for injecting plasticized material under pressure into said cavity when said sections are closed; means engageable with a previously formed strip to remove said strip from said cavity when said sections are open; means to inhibit sideways shrinkage of said strip and means on each of said sections engageable with a different previously formed strip upon the next closing of said sections to position and retain said different strip against the pressure of injection of the next successive strip.
 11. An injection molding apparatus as defined in claim 10, wherein said different strip is the one immediately previously injection molded and said last named means includes spaced projections on one of said mold sections stabilizing said different strip in one direction against the pressure of injection and, said means to inhibit shrinkage comprises different spaced projections on one of the mold sections stabilizing said strip against thermal shrinkage. 